Acrylic and hollow metal composite structure and its composite process

Abstract

The present application relates to the technical field of layered products, in particular to a composite structure of acrylic and hollowed-out metal and a composite process thereof, first, a bonding surface of a lower acrylic plate is subjected to groove milling treatment, a circle of glue grooves is reserved, then a plurality of acrylic pads are laid on the surface of the bonding surface of the acrylic plate, then a hollowed-out metal plate is covered above the acrylic pads, a pouring cavity is formed between the acrylic plate and the hollowed-out metal plate, liquid acrylic composite material is poured into the pouring cavity from the hollowed-out opening of the hollowed-out metal plate, the liquid acrylic composite material in the pouring cavity will flow to all directions due to its own fluidity, and finally all gaps in the pouring cavity are filled. The composite structure of acrylic and hollowed-out metal reserves a pouring space between the hollowed-out metal plate and the acrylic plate, not only makes the composite structure more reliable, but also provides a buffer space for the shrinkage and expansion of the composite structure.

Description

Technical Field

[0001] This invention relates to the field of layered product technology, and in particular to a composite structure of acrylic and perforated metal and its composite process. Background Technology

[0002] With the development of the times, more and more new materials are being applied to architectural and landscape design. Acrylic materials are widely used by designers because of their advantages such as good light transmission, low density, and good weather resistance. In order to better highlight the diversity of design, acrylic is also often used in combination with metal materials such as stainless steel.

[0003] However, engineers encounter numerous problems when combining two different materials. First, acrylic and metal have different coefficients of thermal expansion, resulting in varying degrees of expansion and deformation at the same temperature. When the composite size is small, the difference in expansion and deformation is minimal and does not significantly impact structural stability. However, when the composite size exceeds a certain limit, the difference in expansion and deformation becomes substantial, causing the composite material to fracture and detach from the point of bonding. Second, the conventional method for bonding acrylic with other materials involves an encapsulation process, where liquid acrylic is used to encapsulate other materials, which then solidify to form a composite.

[0004] When the design requires attaching a metal plate to the acrylic surface, the embedding process cannot be used for material bonding. At the same time, if conventional glue is used for dot bonding, it cannot meet the stress requirements after the two materials are bonded together. Furthermore, in order to better showcase the transparency of acrylic, the designers often design the metal plate attached to the surface as a hollow structure. When illuminated, the glue marks at the bonding point of the two materials are very obvious, like patches, affecting the overall aesthetics. Summary of the Invention

[0005] To address the issues of poor adhesion and aesthetic impact of existing adhesive bonding methods for metal and acrylic, this invention provides a composite structure and process for acrylic and perforated metal. By reserving a casting space between the perforated metal plate and the acrylic plate, the composite structure is not only more robust but also provides a buffer space for the shrinkage and expansion of the composite structure.

[0006] This invention provides a composite structure of acrylic and perforated metal, comprising an acrylic sheet and a perforated metal sheet. The perforated metal sheet has perforations and includes several acrylic pads placed between the acrylic sheet and the perforated metal sheet, forming a casting cavity for bonding. The casting cavity communicates with the perforations and is filled with liquid acrylic composite material. By using the acrylic pads, a casting cavity for injecting the composite material is created between the acrylic sheet and the perforated metal sheet, facilitating the injection of the composite material through the perforations in the metal sheet and improving bonding stability.

[0007] Furthermore, the acrylic sheet has an adhesive surface that is bonded to the perforated metal sheet. An adhesive groove is formed at the outer edge of the adhesive surface, and the groove is filled with transparent structural adhesive. The use of transparent structural adhesive not only effectively prevents the composite material from flowing out of the gaps around the casting cavity, but also provides better bonding stability at the cavity's sealed boundary compared to conventional adhesive tape.

[0008] Furthermore, transparent structural adhesive is used to fill the space between the acrylic sheet and the perforated metal sheet. The transparent structural adhesive does not protrude from the composite panel structure, resulting in a more aesthetically pleasing appearance.

[0009] Furthermore, the thickness of the acrylic pad is 1.5-3mm.

[0010] Furthermore, the width of the glue groove is 8-10mm, and the depth of the glue groove is 4-6mm.

[0011] A composite process for an acrylic and perforated metal composite structure includes the following steps:

[0012] Step 1: First, mill grooves around the four edges of the bonding surface of the lower acrylic sheet to leave a groove for adhesive.

[0013] Step 2: After milling, the acrylic sheet is leveled and placed to ensure that it is level overall;

[0014] Step 3: Next, lay multiple acrylic pads on the surface of the acrylic sheet to ensure that the perforated metal sheet is lifted stably.

[0015] Step 4: Then, place the perforated metal plate over the acrylic pad. At this point, a casting cavity is formed between the acrylic plate and the perforated metal plate.

[0016] Step 5: After the perforated metal plate is placed, use an air gun to clean the dust and impurities between the acrylic plate and the perforated metal plate.

[0017] Step Six: Next, fill the glue groove from Step One with transparent structural adhesive to seal the area around the casting cavity;

[0018] Step 7: Pour liquid acrylic composite material into the casting cavity through the perforated opening of the perforated metal plate. After entering the casting cavity, the liquid acrylic composite material will flow outwards due to its own fluidity, eventually filling all the gaps in the casting cavity. After the liquid acrylic composite material solidifies, the composite of the acrylic plate and the perforated metal plate is completed.

[0019] An acrylic pad is laid between the acrylic sheet and the perforated metal sheet to form a casting cavity. After the perforated metal sheet is placed on the acrylic pad, acrylic composite material can be poured directly into the casting cavity through the perforation. The self-flow of the liquid acrylic composite material achieves a stable bond between the acrylic sheet and the perforated metal sheet.

[0020] Furthermore, in step two, the bonding surface of the acrylic sheet is milled to ensure the overall flatness of the acrylic sheet surface.

[0021] Furthermore, the liquid acrylic composite material is poured in multiple times in step seven. This effectively prevents the liquid acrylic composite material from overflowing onto the surface of the perforated metal plate.

[0022] Furthermore, the liquid acrylic composite material in step seven includes MMA adhesive. MMA effectively enhances the adhesion between acrylic and metal.

[0023] Furthermore, the liquid acrylic composite material in step seven also includes MBS toughening agent. MBS increases the toughness of the composite structure, allowing it to expand and contract along with the acrylic and metal, preventing it from falling off.

[0024] The beneficial effects of this invention are as follows:

[0025] (1) The present invention provides a composite structure of acrylic and hollow metal. By reserving a casting space between the hollow metal plate and the acrylic plate, the composite structure after bonding is not only more reliable, but also provides a buffer space for the shrinkage and expansion of the composite structure, thereby effectively preventing the acrylic and metal from breaking apart and falling off due to different expansion at the same temperature.

[0026] (2) The present invention provides a composite process for a composite structure of acrylic and hollow metal. By using multiple injection methods, the liquid acrylic composite material can be effectively prevented from overflowing onto the surface of the hollow metal plate. By adding MMA to the acrylic composite material, the shear resistance, peel resistance and impact stress are improved. By adding MBS, the brittleness of the acrylic composite material after hardening is reduced, and its impact strength and elongation are improved. Attached Figure Description

[0027] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the composite structure;

[0029] Figure 2 This is a schematic diagram of a perforated metal plate;

[0030] In the diagram: 1. Acrylic sheet, 11. Adhesive surface, 12. Adhesive groove, 2. Perforated metal plate, 21. Perforated opening, 3. Acrylic pad, 4. Casting cavity, 5. Transparent structural adhesive. Detailed Implementation

[0031] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0032] To address the issues of poor adhesion and aesthetic impact of traditional acrylic-metal bonding methods, a composite structure of acrylic and perforated metal was designed, such as... Figure 1 and 2 As shown, the structure includes an acrylic sheet 1 and a perforated metal sheet 2. The perforated metal sheet 2 has a perforation 21. It also includes several acrylic pads 3, which are placed between the acrylic sheet 1 and the perforated metal sheet 2, forming a casting cavity 4 for bonding. The casting cavity 4 is connected to the perforation 21 and is filled with liquid acrylic composite material. The acrylic pads 3 create a 2mm gap between the acrylic sheet 1 and the perforated metal sheet 2 for the casting cavity 4, providing a self-flowing space for the composite material. This results in better overall flatness and a stronger bond after bonding, while also providing a buffer for the shrinkage and expansion of the composite structure.

[0033] To prevent acrylic composite material from leaking out of the gaps around the casting cavity 4, the acrylic sheet 1 has an adhesive surface 11 that is bonded to the perforated metal sheet 2. An adhesive groove 12 is formed on the outer edge of the adhesive surface 11, and the groove 12 is filled with transparent structural adhesive 5. This sealing treatment around the casting cavity 4 ensures that the acrylic composite material will not leak out during the subsequent injection process. It also makes the edges of the composite structure easier to handle. The transparent structural adhesive 5, serving as the sealing boundary of the casting cavity 4, offers better stability than conventional tape and provides a tighter bond.

[0034] To ensure the aesthetic appeal of the structure, transparent structural adhesive 5 is filled between acrylic sheet 1 and perforated metal sheet 2, so that transparent structural adhesive 5 does not protrude from the outside of the composite board structure, thus enhancing the aesthetics.

[0035] To ensure bonding stability, the thickness of the acrylic pad 3 is set to 1.5-3mm, preferably 2mm. The width of the adhesive groove 12 is set to 8-10mm, preferably 10mm, and the depth of the adhesive groove 12 is set to 4-6mm, preferably 5mm.

[0036] A composite process for an acrylic and perforated metal composite structure is disclosed, comprising the following steps: Step 1: First, mill grooves around the bonding surface of the lower acrylic sheet 1 to leave a ring of adhesive grooves 12; Step 2: After milling, level the acrylic sheet 1 to ensure its overall horizontality and prevent the composite material from converging in one direction and accumulating during the pouring process, which would affect the bonding effect; Step 3: Next, lay multiple acrylic pads 3 on the bonding surface of the acrylic sheet 1 to ensure stable lifting of the perforated metal sheet 2, creating a cavity between the two sheets. The specific spacing between adjacent acrylic pads 3 is based on the spacing density of the perforations 21 on the perforated metal sheet 2; Step 4: Then, place the perforated metal sheet 2 on top of the acrylic pads 3. At this point, the acrylic sheet 1... Step 5: After the perforated metal plate 2 is placed, use an air gun to clean the dust and impurities between the acrylic plate 1 and the perforated metal plate 2 to ensure that no impurities affect the bonding and overall appearance of the structure; Step 6: Next, use transparent structural adhesive 5 to fill the adhesive groove 12 in Step 1 to seal the perimeter of the casting cavity 4, ensuring that the composite material will not leak from the gaps around the cavity during the later injection process; Step 7: Pour liquid acrylic composite material into the casting cavity 4 through the perforation 21 of the perforated metal plate 2. After entering the casting cavity 4, the liquid acrylic composite material will flow outwards due to its own fluidity, filling all the gaps in the casting cavity 4. After the liquid acrylic composite material solidifies, the composite of acrylic plate 1 and perforated metal plate 2 is completed.

[0037] To ensure the overall flatness of the acrylic surface, the bonding surface 11 of the acrylic sheet 1 is milled before lamination. Since the large-format perforated metal sheet 2 may deform and warp during positioning and hoisting, there is still a possibility of composite material overflowing onto the metal sheet surface during the pouring process. To address this, the composite material can be poured in small amounts multiple times. The specific spacing between adjacent acrylic pads 3 is determined by the density of the perforations 21 on the perforated metal sheet 2. If the perforations 21 on the metal sheet are dense, the pads are laid in a crisscross pattern; if the perforations 21 are sparse, they are laid in a staggered pattern. The spacing between the pads is 200mm.

[0038] The main component of acrylic composites is MMA (methyl methacrylate), a common composite material used for bonding acrylic pieces together. MMA cures rapidly at room temperature and achieves full bond strength shortly after application. This adhesive is resistant to shear, peel, and impact stresses. From a technical perspective, the bonding process works through an exothermic polymerization reaction, where monomer molecules react chemically to form polymer chains. This means the adhesive maintains flexibility while forming a strong bond. These adhesives can bond different materials with varying degrees of flexibility, such as metals and plastics. Unlike some other structural adhesives (such as two-component epoxy resins), MMA does not require heating to cure. MMA is less brittle than epoxy resins, can fill large gaps, has higher bond strength than urethane, better impact resistance and fatigue resistance, good chemical and environmental resistance, and a fast curing speed. The tensile strength of the composite bond can reach 65% of the tensile strength of acrylic. Furthermore, the colorless and room-temperature curing properties of MMA are well-suited to the transparent material, acrylic.

[0039] When used in the composite of acrylic and metal materials, to address the issue of different displacements caused by the different linear expansion coefficients of the two materials, the formulation needs to be optimized and modified. This involves increasing the extensibility after curing, reducing brittleness, increasing toughness, and improving load-bearing capacity. The goal is to ensure the composite material deforms and shrinks along with the acrylic and metal during expansion and displacement, while retaining the original adhesive strength. Therefore, a small amount of MBS toughening agent (approximately 58g MBS per kg MMA) is added to the acrylic composite to reduce brittleness after hardening and improve its impact strength and elongation. Toughening agents are additives that reduce the brittleness of composite materials and improve their impact resistance. MBS, for example, effectively increases the toughness of various plastic materials through special chemical polymerization and physical action, even in small amounts. Thus, a composite material with a special ratio of MMA and MBS can bond two different materials while providing space for expansion and displacement, effectively preventing the two materials from splitting and detaching due to different expansion at the same temperature.

[0040] The above description is illustrative only and not restrictive of the present invention. Those skilled in the art will understand that many modifications, variations or equivalents can be made without departing from the spirit and scope defined by the appended claims, and all such modifications, variations or equivalents will fall within the protection scope of the present invention.

Claims

1. A composite structure of acrylic and perforated metal, comprising an acrylic sheet (1) and a perforated metal sheet (2), wherein the perforated metal sheet (2) has a perforation (21), characterized in that, It also includes several acrylic pads (3), which are placed between the acrylic plate (1) and the hollow metal plate (2) to stably lift the hollow metal plate (2) so that a casting cavity (4) for bonding is formed between the acrylic plate (1) and the hollow metal plate (2). The casting cavity (4) is connected to the hollow opening (21), and liquid acrylic composite material is poured into the casting cavity (4). The acrylic sheet (1) has an adhesive surface (11) that is bonded to the hollow metal sheet (2). The outer edge of the adhesive surface (11) is provided with a glue groove (12), and the glue groove (12) is filled with transparent structural adhesive (5). The transparent structural adhesive (5) is filled between the acrylic plate (1) and the hollow metal plate (2); The liquid acrylic composite material includes MMA binder; The liquid acrylic composite material also includes MBS toughening agent.

2. The composite structure of acrylic and perforated metal according to claim 1, characterized in that: The thickness of the acrylic pad (3) is 1.5-3mm.

3. The composite structure of acrylic and perforated metal according to claim 1, characterized in that: The width of the glue groove (12) is 8-10mm, and the depth of the glue groove (12) is 4-6mm.

4. The composite process for a composite structure of acrylic and perforated metal according to claim 1, characterized in that: Step 1: Mill grooves around the bonding surface of the lower acrylic sheet (1) to leave a groove for adhesive (12). Step 2: After milling the acrylic plate (1), adjust its level and place it to ensure that it is level. Step 3: Lay multiple acrylic pads (3) on the bonding surface of the acrylic sheet (1) to ensure that the hollow metal sheet (2) is lifted stably; Step 4: Place the perforated metal plate (2) over the acrylic pad (3). At this time, a casting cavity (4) is formed between the acrylic plate (1) and the perforated metal plate (2). Step 5: After the perforated metal plate (2) is placed, use an air gun to clean the dust and impurities between the acrylic plate (1) and the perforated metal plate (2); Step 6: Fill the glue tank (12) in Step 1 with transparent structural adhesive (5) and seal the casting cavity (4) from all sides; Step 7: Pour liquid acrylic composite material into the casting cavity (4) through the perforated opening (21) of the perforated metal plate (2). After entering the casting cavity (4), the liquid acrylic composite material will flow outwards due to its own fluidity, filling all the gaps in the casting cavity (4). After the liquid acrylic composite material solidifies, the composite of acrylic plate (1) and perforated metal plate (2) is completed.

5. The composite process for a composite structure of acrylic and perforated metal according to claim 4, characterized in that: The bonding surface (11) of the acrylic sheet (1) in step two is milled.

6. The composite process for a composite structure of acrylic and perforated metal according to claim 4, characterized in that: The liquid acrylic composite material injected in step seven is injected multiple times.

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